start + dpf problems, forscan output

[fabcal]

Hi

Ford Transit 110 T350 2007 LWD 2.2

Bought it used a few weeks ago with the following issues:
- start problems
- black exhaust
- emergency mode due, according to ford mechanic, to faulty egr. Been driven with faulty egr for an unknown distance but at least 500 km I assume, possible much more.

Got a guy to delete egr and remove the emergency mode. Drove 140 km at 2500 rpm thereafter. The exhaust is ways better now but still not good enough.

I have now also blocked the intake to the egr physically. Friend says I should block the outtake as well because of risk of turbulence. Is that correct?

I got an extended license to forscan on pc and tried to check differential exhaust pressure but I can't find it in the parameters. Is it possible that my model doesn't have pressure sensors for the dpf? I can't see any sensors when looking at the dpf (not on forscan but looking at the physical dpf). I can't see a vaporizer either. If so is their any way to assess dpf health with forscan? If not, should I take the massive improvement of exhaust as a sign that regen is working fine and it's only going to improve further. I'm about to drive 2x2200 km provided I feel confident the van is in good enough shape.

Start issue
2 batteries. New start battery, the other battery in good health (has a color indicator). Earthing doesn't look good though.
The engine fires but stops immediately. Doesn't help to crank further. Sometimes it starts, and those times it runs like a clock. It really it's a sensor issue. Feels like there's not enough fuel coming to the engine or the idle rpm is too low. I'm disconnecting or reconnecting the MAF between each try. It seemed to work originally because one disconnect/reconnect was enough but it isn't anymore so I don't know.

Attaching screenshots from forscan and pasting DTC + car info below.

DTC OUTPUT
===OBD2_PCM DTC None===
Successful DTC reading, no error codes found

Module: On Board Diagnostic II (PCM)

===END OBD2_PCM DTC None===

===PCM DTC None===
Successful DTC reading, no error codes found

Module: Powertrain Control Module

===END PCM DTC None===

===ABS DTC None===
Successful DTC reading, no error codes found

Module: Antilock braking system

===END ABS DTC None===

===BCMii DTC B1052:29-08===
Code: B1052 - Rear Washer Switch

Additional Fault Symptom (:29):
- Signal Invalid

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC B1052:29-08===

===BCMii DTC B1051:23-08===
Code: B1051 - Front Washer Switch

Additional Fault Symptom (:23):
- Signal Stuck Low

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC B1051:23-08===

===BCMii DTC B1052:23-08===
Code: B1052 - Rear Washer Switch

Additional Fault Symptom (:23):
- Signal Stuck Low

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC B1052:23-08===

===BCMii DTC B10A2:35-08===
Code: B10A2 - Crash Input

Additional Fault Symptom (:35):
- Signal High Time Greater Than Maximum

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC B10A2:35-08===

===BCMii DTC U0151:00-08===
Code: U0151 - Lost Communication With Restraints Control Module

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC U0151:00-08===

===BCMii DTC U0121:00-08===
Code: U0121 - Lost Communication With Anti-Lock Brake System (ABS) Control Module 'A'

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC U0121:00-08===

===BCMii DTC U0100:00-08===
Code: U0100 - Lost Communication With ECM/PCM A

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC U0100:00-08===

===BCMii DTC U0100:87-08===
Code: U0100 - Lost Communication With ECM/PCM A

Additional Fault Symptom (:87):
- Missing Message

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC U0100:87-08===

===BCMii DTC B10D7:87-08===
Code: B10D7 - PATS Key

Additional Fault Symptom (:87):
- Missing Message

Status (-08):
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Body Control Module

===END BCMii DTC B10D7:87-08===

===RCM DTC U0155===
Code: U0155 - Lost Communication With The Instrument Panel Cluster Control Module

Module: Restraint Control Module

===END RCM DTC U0155===

===ACM DTC None===
Successful DTC reading, no error codes found

Module: Audio Control Module

===END ACM DTC None===

===IPC DTC None===
Successful DTC reading, no error codes found

Module: Instrument Panel Control Module

===END IPC DTC None===


__________________________

CAR INFO
Interface:
Type: FTDI #1:D39ZTN3N, 3000000 bps
Adapter: vLinker FS v2.3.04 MIC3322 V2.3.04 (ELM327 v2.3)
Min.delay: 3 ms ( Excellent)
Errors: None

Vehicle:
Model: Ford Transit
Engine: Duratorq Turbo Diesel Common Rail Injection
Capacity: 2.2L
Year: 2007
Month: 11
Generation: 2006.5
Fuel: Diesel
VIN: WF0XXXTTFX7M35886

OBD2_PCM - On Board Diagnostic II (PCM)
Hardware type: DCU-101
VIN: WF0XXXTTFX7M35886

PCM - Powertrain Control Module
Part number: 6C11-12A650-CV
Calibration level: 6C11-12A650-CV (latest known: 6C11-12A650-CZ)
Strategy : 6C11-12K532-CV
Calibration: 6C11-12K532-CV
Hardware type: DCU-101
VIN: WF0XXXTTFX7M35886

ABS - Antilock braking system
Part number: 8C11-2C405-BB
Calibration level: 8C11-2C405-BB
Strategy : 8C1T-14C036-BB
VIN: WF0XXXTTFX7M35886

BCMii - Body Control Module
Part number: 8C1T-14A073-CB
Calibration level: 8C1T-14A073-CB (latest known: 8C1T-14A073-CG)
Strategy : 8C1T-14C094-AB
VIN: WF0XXXTTFX7M35886

RCM - Restraint Control Module
Part number: 6C1T-14B056-AE
Software version: v1

ACM - Audio Control Module
Part number: 6C1T-18C815-AJ
Calibration level: 6C1T-18C815-AJ
Strategy : 6C1T-14C044-AG
VIN: _________________

IPC - Instrument Panel Control Module
Part number: 8C1T-10849-CC
Calibration level: 8C1T-10849-CC (latest known: 8C1T-10849-XB)
Strategy : 8C1T-14C026-AC
VIN: WF0XXXTTFX7M35886

[Altransit]

Welcome to the forum

Just my tuppenceworth to start with:-

If yours is a 2007, it will be a Euro 4, so shouldn't have a DPF and vapouriser, if so, there are no regens to worry about

[fabcal]

Thanks
Do you mean no vapouriser but a DPF and an EGR?
Forscan allows DPF static regeneration. How can I check the dpf health or whether I should run the procedure. As mentioned I can't find the differential pressure in the list of monitorable parameters.

Since I submitted my post I've followed the advice found on the forum and reset PRV open duration and open count. It seems to have fixed the starting problem. I'll do a learn of fuel injection pump and fuel injector pilot correction later, needs warm engine.

A little concerned about DTC U0155 Lost Communication With The Instrument Panel Cluster Control Module. Is it a sign of bad earthing, which I suspect I have?

[fabcal]

I confirm the start problem is solved.
So I went for a test drive.
soot_oil, mg shows ca. 24000, no idea if it's an ok value
Have still not found out how to measure dpf health.

Tried to run the learn on the pump but it failed:
initialization failure. Suspect an intermittent fault:
- fuel rail pressure sensor
- short to VBATT
I've measured FRP live and it shows from ca. 20000 kPa and up depending on gas pedal position. So I'm assuming it's a bad earthing, right? And the way to fix it is to clean up the two connections beneath the cooling fluid expansion reservoir. Correct? Of course they are so rusted I haven't been able to unscrew them.

As stated earlier I've reset PRV open count and open duration (and it fixed the start problem).
Now I'm noticing vibration when running at ca. 1500 rpm with low rail pressure. I'm hoping it will disappear when / if I manage to run the learns on the injection pump and the injectors.

[knobby1]

Thanks
Do you mean no vapouriser but a DPF and an EGR?
Forscan allows DPF static regeneration. How can I check the dpf health or whether I should run the procedure. As mentioned I can't find the differential pressure in the list of monitorable parameters.

Since I submitted my post I've followed the advice found on the forum and reset PRV open duration and open count. It seems to have fixed the starting problem. I'll do a learn of fuel injection pump and fuel injector pilot correction later, needs warm engine.

A little concerned about DTC U0155 Lost Communication With The Instrument Panel Cluster Control Module. Is it a sign of bad earthing, which I suspect I have?

As mentioned by Altransit...your 2007 shouldn't have a DPF...these weren't introduced until Sept 26 2011 when Euro-5 Transits started. There were a few rare Euro-4 Mk7's from ~October of 2008 with a DPF but they were usually retricted to Government agency fleet vehicles etc.. Nobody in their right mind would intentionally buy one. Do you have wires and vaporiser going to a DPF on the exhaust..?? You do have an EGR though.

Lord Knobrot

[fabcal]

Thank you very much.
I assumed presence of an EGR meant there also was a DPF.
No, I definitely can't find a vapouriser. I thought the large cylinder right beneath the turbo, on the exhaust line, was a DPF.

In another thread you wrote about changing the injection correction factors before doing the learns. Am planning to try tomorrow. Do I download these factors or does forscan have them?

[metalworker0]

I thought the large cylinder right beneath the turbo, on the exhaust line, was a DPF.

its a catalyst

all the best.mark

[fabcal]

What I have is the same as on the picture.
I thought the catalyst was the flexible part in the middle. Does that part have no other function than flection?

[knobby1]

What I have is the same as on the picture.
I thought the catalyst was the flexible part in the middle. Does that part have no other function than flection?

The catalyser "CAT" is the large cylinder piece under the turbo...the flex pipe is just that, a flexible pipe, it serves no other purpose....if it was a solid pipe, it would probably crack after a short period of heat cycles, many vehicles have them.

You do not have a DPF.

Lord Knobrot

[tranmx2]

Button DTC on left under the car!.
Previously set DTC. In Forscan - in DTC - click on RESET (delete/clear) at the bottom lhs.

Forscan reset DTC.JPG

= Removes all of the shown DTCs. Restart FORSCAN do another scan - Check which DTCs show when in the DTC mode.
One needs to learn how to use Forscan. SY diagnostics and others on youtube.

[fabcal]

Thank you both very much.
Still a lot to fix but it has helped me get further.

[Stevelien]

Glad you sorted this out. Good luck!

[fabcal]

I tried to run the learn on the pump again, this time with batteries freshly charged (and warm engine) but same error at 47% if I remember correctly, at which point the engine was running:
Initialization failure. Suspect an intermittent fault:
- fuel rail pressure sensor
- short to VBATT
Forscan was showing 14.7 V on the battery and my FRP measures pressure when I check live data. And FRP measured and desired are very close.

Should I change the FRP sensor?
Should I clean up all the earths?
Other suggestions?

I tried putting the injector correction factor codes into the pcm before pump learn, as recommended by Lord Knobrot, but I have no idea which codes to put in. Can read the current codes but no idea how to assess whether they're correct.

[knobby1]

I tried to run the learn on the pump again, this time with batteries freshly charged (and warm engine) but same error at 47% if I remember correctly, at which point the engine was running:
Initialization failure. Suspect an intermittent fault:
- fuel rail pressure sensor
- short to VBATT
Forscan was showing 14.7 V on the battery and my FRP measures pressure when I check live data. And FRP measured and desired are very close.

Should I change the FRP sensor?
Should I clean up all the earths?
Other suggestions?

I tried putting the injector correction factor codes into the pcm before pump learn, as recommended by Lord Knobrot, but I have no idea which codes to put in. Can read the current codes but no idea how to assess whether they're correct.

Injector 16 digit correction factor codes are printed on the electrical connector of each injector. The writing is tiny, use your phone to take aphoto and zoom in to read them.

If the system fails the learns, you may have injector problems.

Lord Knobrot

[fabcal]

Thank you very much.
Ok, I checked but couldn't find anything. Will look more.

And I forgot something. The right-hand-side end of the cable that goes to the injectors is not connected. Have been looking around in vain for a place to connect it.